Stator core and motor using the same

ABSTRACT

The present invention relates to a stator core for improving the fixing properties of a magnet wire, and a motor in which the same is applied. Provided is a stator core which comprises a protrusion pattern part for fixing the distal end portion of a magnet wire, and thus eliminates a process of fixing the wire using a separate member during a wiring process, thereby improving processability and inhibiting an insulating film of the magnet wire from being damaged by an external force such as vibration.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.17/229,434, filed Apr. 13, 2021; which is a continuation of U.S.application Ser. No. 16/813,014, filed Mar. 9, 2020, now U.S. Pat. No.11,005,314, issued May 11, 2021; which is a continuation of U.S.application Ser. No. 15/541,673, filed Jul. 5, 2017, now U.S. Pat. No.10,622,850, issued Apr. 14, 2020; which is the U.S. national stageapplication of International Patent Application No. PCT/KR2015/014092,filed Dec. 22, 2015, which claims priority to Korean Application No.10-2015-0001326, filed Jan. 6, 2015, the disclosures of each of whichare incorporated herein by reference in their entirety

TECHNICAL FIELD

The teachings in accordance with exemplary and non-limiting embodimentsof this disclosure relate generally to a stator core improved infixability of magnet wire and a motor using the same.

BACKGROUND ART

In general, a motor is mainly composed of a stator and a rotor, and thestator is wound with a coil, and the rotor is coupled with a magnet tocause rotating due to mutual electromagnetic action with the magnet. Thestator is formed with a unit core and a coil, and recently, a pluralityof divided coils is connected in a ring shape to be used as a stator. Aninsulator (hereinafter referred to simply as “insulator”) is inserted toinsulation between the core and the coil.

Particularly, the insulator has a structure where a coil is wound, andwhen a wire, generally called a magnet wire, is wound on the insulator,an outermost coil is not fixed to generate damage or cut problem on aninsulated film of the magnet wire due to trembling phenomenon caused byoutside vibration.

DETAILED DESCRIPTION OF THE INVENTION Technical Subject

The teachings in accordance with exemplary and non-limiting embodimentsof this disclosure are to provide solve the abovementioned problem byproviding a protruding pattern part fixing a distal end of a magnet wireto remove a wire-fixing operation using a separate member during wiringoperation, whereby a processibility can be improved and a stator coreinhibiting damage to insulated film of the magnet wire caused by outsideforce such as vibration can be provided.

Technical Solution

In one general aspect of the present invention, there is provided astator coil, the stator coil comprising:

a unit stator core provided with a tooth protruded from a head part;

an insulation member coupled to the unit stator core and wound with acoil; and

a coil-fixing protrusion pattern part provided on a surface of theinsulation member.

Preferably, but not necessarily, the insulation member may include abody part wound with a coil and provided with a winding guide groove,and an edge part extended from the body part and arranged with theprotrusion pattern part.

Preferably, but not necessarily, the protrusion pattern part may berealized by an embossed 3D (dimensional) structure on a surface of theedge part.

Preferably, but not necessarily, a first bank angle may be provided on asurface of the 3D structure from an outermost marginal part of theprotrusion pattern part to a body part side.

Preferably, but not necessarily, the protrusion pattern part may bearranged by being extended along a lengthwise direction of theinsulation member.

Preferably, but not necessarily, the stator core may be further providedat an opposite surface realized with the first bank angle with afixation groove pattern that is concaved to a center of the 3Dstructure.

Preferably, but not necessarily, the bank angle may be an acute angleformed by an extension line from surface of the edge part and anextension line from the 3D structure.

Preferably, but not necessarily, the protrusion pattern part may includea discrete part which is fixed at one end to the surface of the edgepart, and which is discrete at the other end from the surface of theedge part.

Preferably, but not necessarily, a discrete width of the discrete partmay be uniform.

Preferably, but not necessarily, the protrusion pattern part may befixed at one end near to the body part to the surface of the edge part,and may be formed at the other end with a bank angle toward the bodypart.

Preferably, but not necessarily, the protrusion pattern part may befixed at the other end distanced from the body part to the surface ofthe edge part, and the other end may form a bank angle toward the bodypart.

Preferably, but not necessarily, a second bank angle may be formed at asurface of an opposite 3D structure formed with the bank angle.

Preferably, but not necessarily, the second bank angle may have an anglegreater than that of the bank angle.

In another general aspect of the present disclosure, there is provided amotor, the motor comprising:

a motor housing;

a stator coil mounted at the motor housing and including a plurality ofunit stator coils each having a tooth protruded from a head part, aninsulator and a coil;

a rotor rotatably mounted at a center of the stator, and including athrough hole formed at a center and a magnet module; wherein

the stator core includes a unit stator coil provided with a toothprotruded from the head part, and an insulation member coupled to theunit stator coil and wound with a coil, and wherein

a surface of the insulation member includes at least one coil fixationprotrusion pattern part.

Advantageous Effects of the Invention

The advantageous effect according to exemplary embodiment of the presentdisclosure is that a protruding pattern part fixing a distal end of amagnet wire is provided to remove a wire-fixing operation using aseparate member during wiring operation, whereby a processibility can beimproved, and damage to insulated film of the magnet wire caused byoutside force such as vibration can be inhibited.

Another advantageous effect is that prevention of short-circuit causedby friction between winding portions of a magnet wire from outsidevibration allows short-circuit removal operation realized by using aseparate member, and separate after treatment-process for inhibitingdamage to insulated film of wire becomes unnecessary to thereby improvethe processibility.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a separable perspective view exemplifying a coupled statebetween structure of unit stator core and insulation member in statorcore according to an exemplary embodiment of the present disclosure.

FIG. 2 is a schematic coupled perspective view of FIG. 1.

FIG. 3 is a schematic view illustrating an insulation member beingcoupled to a unit stator core and the insulation member being wound witha coil according to an exemplary embodiment of the present disclosure.

FIG. 4 is a plan view illustrating an insulation member of FIG. 3 seenfrom above.

FIG. 5 is an enlarged conceptual view illustrating an arrangementrelationship of major elements between protrusion pattern part and acoil.

FIGS. 6 and 7 are schematic views illustrating a protrusion pattern partaccording to another exemplary embodiment of the present disclosure.

FIG. 8 is a schematic view illustrating a protrusion pattern partaccording to still another exemplary embodiment of the presentdisclosure.

FIG. 9 is a schematic conceptual view illustrating a structure of an EPSmotor with a unit stator core according to an exemplary embodiment ofthe present disclosure.

BEST MODE

Reference will now be made in detail to embodiments, examples of whichare illustrated in the accompanying drawings. Like reference numeralsdesignate like elements throughout the specification, and anyoverlapping explanations that duplicate one another will be omitted.Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section.

FIG. 1 is a separable perspective view exemplifying a coupled statebetween structure of unit stator core and insulation member in statorcore according to an exemplary embodiment of the present disclosure, andFIG. 2 is a schematic coupled perspective view of FIG. 1.

Referring to FIGS. 1 and 2, a stator core according to an exemplaryembodiment of the present disclosure may include a unit stator core(110) provided with a tooth (112) protruded from a head part, aninsulation member (200) coupled to the unit stator core (110) and woundwith a coil, and at least one coil-fixing protrusion pattern part (230)provided on a surface of the insulation member (200).

When the protrusion pattern part (230) is wound with a coil later, anoutermost part is inhibited from being deviated to outside after thecoil is wound, and an operation of temporarily fixing a coil using aseparate member (tape and the like) or an operation of removing can beeliminated to improve the processibility, whereby an entire coil can bestably fixed to thereby inhibit a short-circuit caused by frictionbetween coils.

Although drawings have exemplified a structure where the insulationmember (200) is divided to two sections, the present disclosure is notlimited thereto, and although the unit stator core has been exemplified,the stator core conventionally forms a ring-shaped structure by couplinga plurality of unit stator cores.

The insulation member (200) may be such that a pair of mechanismsprovided at an inside with a space (S) accommodating the tooth (112) isarranged in a plate shape each mechanism facing the mechanism, and aconnection part (222) connecting an upper surface of the pair ofmechanisms is provided.

Hereinafter, a portion formed by the pair of mechanism with a windingguide groove (221) wound with a coil is defined as a “body part (220)”,and a portion extended to a lateral surface from the body part (220) isdefined as an “edge part (210)”. In addition, a distal end of the bodypart (220) may be formed with a coupling part (223) provided by beingprocess in thickness thinner than that of the mechanism. The couplingpart (223) may be realized at a distal end of the body part at a lowersurface of the insulation member in the same structure, as illustratedin the drawing. Thereafter, the coupling parts (223) formed at distalends of an upper surface and a lower surface of the insulation membermay be coupled by being overlapped.

In particular, a protrusion pattern part (230) may be provided on asurfaced of the edge part (210) to fix a coil when the coil is woundlater according to the exemplary embodiment of the present disclosure.

The protrusion pattern part (230) may be realized with a 3D(dimensional) structure in an embossed protruding shape, and may bearranged in one or in a plurality of numbers on the surface of the edgepart (210) to fix the coil.

FIG. 3 is a schematic view illustrating an insulation member beingcoupled to a unit stator core and the insulation member being wound witha coil according to an exemplary embodiment of the present disclosure,FIG. 4 is a plan view illustrating an insulation member of FIG. 3 seenfrom above, and FIG. 5 is an enlarged conceptual view illustrating anarrangement relationship of major elements between protrusion patternpart and a coil.

Referring to FIGS. 3, 4 and 5, the protrusion pattern part (230) may beformed on the surface of the edge part (210) in an embossed 3Dstructure, as explained before. Furthermore, the protrusion pattern part(230) may be provided with a first bank angle (01) on one surface (231)from an outermost marginal area to a body part (220) side. The firstbank angle (01) may function to perform as a guidance to allow the coilto easily slide when the coil (C) is wound on the body part, to allowthe coil to be tightly attached to the body part, and to allow a windingof coil to be easily wound on the winding guide groove (221). The term“bank angle” as used herein refers to a bevel (e.g., in the surface ofprotrusion pattern part (230)), as depicted in FIGS. 5-8 (as θ, θ1, θ2,θ3, θ4, and θ5).

Overall, the protrusion pattern part (230), as illustrated in FIG. 3,may inhibit a wire from being omitted or from being deviated after thecoil (C) is wound by fixing the coils (C1, C2) protruding to theoutermost area at an outer area. Furthermore, an opposite area where thefirst bank angle (θ1) is formed may be further provided with a secondbank angle (θ2), where the second bank angle (θ2) may inhibit the coilfrom being spread to outside by tightly holding the coil. In this case,the first bank angle (θ1) may be preferably formed with an acute angleto guide the smooth winding of the coil, and the second bank angle (θ2)may be formed at an angle greater than the first bank angle (θ1).

In addition, the protrusion pattern part (230) is not limited to a dotshape according to an exemplary embodiment of the present disclosure,and the protrusion pattern part (230) may be arranged by being extendedalong a lengthwise direction of the insulation member. In this case, theoutermost coil may be fixed across the board to a lengthwise directionafter finish of winding to enable a further increase in fixing power.

FIGS. 6 and 7 are schematic views illustrating a protrusion pattern partaccording to another exemplary embodiment of the present disclosure.

Referring to FIGS. 6 and 7, in furtherance to forming a protrusionpattern part (240) in a 3D structure, the structure may be formed insuch a fashion that one distal end is fixed to a surface of the edgepart, and the other distal end is discrete from the surface of the edgepart. This discrete structure enables a discrete part to have apredetermined elasticity and to doubly increase the fixing power of thecoil, and overall, motion of magnet wire can be inhibited. Theprotrusion pattern part (240) may be injection molded with a samematerial as that of the insulation member (210), or may be realized byattachment of a separate structure.

To be more specific, as illustrated in FIG. 6, the protrusion patternpart (240) may be fixed, at one distal end nearer to the body part, to asurface of the edge part (210) while the other distal end (241) may beformed with a second bank angle (θ3) toward a body part side. The thirdbank angle (θ3) may be formed by an acute angle and may further easinessof winding, which has been already set out as above.

Furthermore, an opposite side (242) of the third bank angle (θ3) may beformed with a fourth bank angle (θ4) to strengthen the fixibility.

FIG. 7 is an exemplary embodiment realized in inverse manner from thatof FIG. 6, where a protrusion pattern part (250) may be realized, andthe other distal end distant from the body part may be fixed to asurface of the edge part (210), and the other distal end may be formedwith a fifth bank angle (θ5) toward a body part side at an acute angle.In this structure, in the aspect of improving usage of elasticitysimilar to the structure in FIG. 6, fixibility can be more enhanced byway of possible application of a more direct pressure to a coil thanthat of FIG. 6.

Furthermore, as elaborated in the previous exemplary embodiment, a sixthbank angle (θ6) may be also formed at the other distal end (252) of theprotrusion pattern part (250), and therefore, the shape and effect ofwhich will be omitted in further explanation thereto.

FIG. 8 is a schematic view illustrating a protrusion pattern partaccording to still another exemplary embodiment of the presentdisclosure.

The characteristic of FIG. 8 in terms of structure is that, althoughFIG. 8 may be similar to FIG. 5 in that FIG. 8 is also formed with a 3Dstructure with a bank angle, an opposite side where a seventh bank angle(θ7) is formed may be further realized with a fixation groove pattern(232) concaved to a center side of the 3D structure.

In this case where the fixation groove pattern (232) is further formed,it should be apparent that fixibility can be further enhanced by adistal end of an outermost coil being inserted into the fixation groovepattern (232) in the structure of FIG. 3. It should be apparent thatthis structure may be changed to allow the fixation groove pattern (232)to be realized even in the exemplary embodiment of FIG. 6.

Hereinafter, an exemplary embodiment of an EPS motor with a unit statorcore according to an exemplary embodiment of the present disclosure willbe described with reference to FIG. 9. FIG. 9 is a schematic conceptualview illustrating a structure of an EPS motor with a unit stator coreaccording to an exemplary embodiment of the present disclosure.

However, it should be apparent that the stator core according to theexemplary embodiment may be applied to other various motors. An EPSmotor will be exemplified and explained in the present exemplaryembodiment.

Referring to FIG. 9, a motor housing (H) and a bracket (30) coupled withthe motor housing (H) may be provided. The housing (H) may be opened atan upper surface, and may be protrusively formed at a center with asupport pipe (11). Furthermore, the bracket (30) may be coupled to anupper surface of the housing (H) to form an inner space. The supportpipe (11) may be mounted with a first bearing (31), and the bracket (30)may be mounted with a second bearing (32). The first and second bearings(31, 32) may be supportively contacted by a rotation shaft (400), andthe rotation shaft (400) may be supported at an upper surface by thesecond bearing (32), and may be supported at a lower surface by thefirst bearing (31).

An upper end part of the rotation shaft (400) may be protruded to anupper side through the bracket (30), and the rotation shaft (400) may becoupled to a mechanism (60) connected to a steering shaft (not shown).The housing (H) may be mounted therein with a stator and a rotor. Therotor may include a rotor core (320) coupled to the rotation shaft (400)and a magnet (310) coupled to a periphery of the rotor core (320).Although the exemplary embodiment has explained and illustrated astructure in which a magnet is coupled to a periphery of a rotor core,unlike this structure, the exemplary embodiment may be realized by astructure in which a magnet is inserted into a rotor core. Furthermore,the stator may include a stator core (200) arranged between a magnet(310) and a housing (110), and a coil (C) wound on a stator core (200).

The stator core and an insulated structure forming the stator may beapplied with the structure of the exemplary embodiment explained inFIGS. 1 to 4.

In the above structure, the magnetic field generated from the stator andan electric field generated from the motor may be interacted to eachother to rotate the rotation shaft (400).

Meantime, the rotation shaft (400) may rotate along with a sensing plate(190) by being coupled to the rotation shaft (400), and the sensingplate (190) may be mounted with a sensing magnet (50). The bracket (30)may be mounted with a circuit board (10), the circuit board (10) may bemounted with a sensing element (20) opposite to the sensing magnet (50).The sensing element (20) may detect a degree of the sensing magnet (50)being rotated to allow the sensing magnet (50) to detect a degree of thesensing plate (190) coupled by the sensing magnet (50) and the rotationshaft (400) being rotated.

Thus, generation of detachment of magnet wire by vibrations generatedfrom the above rotations can be mitigated by the insulation memberprovided with a protrusion pattern part according to the exemplaryembodiments of the present disclosure, whereby the motor itself can beenhanced in its reliability.

Although the abovementioned embodiments according to the presentinvention have been described in detail with reference to the abovespecific examples, the embodiments are, however, intended to beillustrative only, and thereby do not limit the scope of protection ofthe present invention. Thereby, it should be appreciated by the skilledin the art that changes, modifications and amendments to the aboveexamples may be made without deviating from the scope of protection ofthe invention.

1. A motor, the motor comprising: a housing; a stator disposed in thehousing; a rotor disposed in the stator; and a shaft disposed in therotor, wherein the stator includes a stator core, an insulator coupledto the stator core, and a coil wound on the insulator, wherein theinsulator includes a body part on which the coil is wound, an edge partextending from the body part, and a protrusion part protruding from theedge part, wherein the protrusion part is formed at the end of the edgepart, and wherein the coil is disposed between the protrusion part andthe body part
 2. The motor of claim 1, wherein the insulator includes afirst insulator coupled to one side of the stator core and a secondinsulator coupled to an other side of the stator core, and wherein theprotrusion part is disposed adjacent to an upper end of the firstinsulator or adjacent to a lower end of the second insulator.
 3. Themotor of claim 1, wherein the protrusion part protrudes in the shaftdirection from an inner circumferential surface of the edge part.
 4. Themotor of claim 2, wherein the protrusion part is disposed on at leastone side of the first insulator and the second insulator.
 5. The motorof claim 2, wherein the protrusion part is disposed closer to one sidethan to an other side of the body part of the first insulator.
 6. Themotor of claim 2, wherein the first insulator is coupled in onedirection of the stator core, and wherein the second insulator iscoupled in an other direction of the stator core.
 7. The motor of claim2, wherein a length of the protrusion part relative to the axialdirection of the shaft is smaller than a length of the first insulator.8. The motor of claim 1, wherein the protrusion part includes a firstsurface extending from an outermost edge part of the protrusion part inthe direction of the body part and a second surface disposed opposite tothe first surface, and has first and second inclination angles, whereinthe first inclination angle is smaller than the second inclinationangle.
 9. The motor of claim 8, wherein the protrusion part includes asurface parallel to the third surface.
 10. The motor of claim 1, whereinthe protrusion part includes a second surface extending from an innersurface of the edge part and a first surface extending from the secondsurface, wherein the protrusion part includes an imaginary third surfaceparallel to the inner surface of the edge part and a first inclinationangle formed by the first surface, and a second inclination angle formedby the second surface and the third surface, and wherein the firstinclination angle is smaller than the second inclination angle.
 11. Themotor of claim 1, wherein the protrusion part is disposed adjacent oneend of the edge part, and a length of the protrusion part is less thanhalf of a length of the body part relative to the axial direction of theshaft.
 12. The motor of claim 1, wherein one surface of the protrusionpart includes a curved shape and the curved shape is in contact with thecoil.
 13. The motor of claim 1, wherein the stator core includes a headpart and a tooth part extending from the head part, and wherein at leasta portion of the protrusion part is disposed outside an end of the headpart with respect to the body part.
 14. A motor, the motor comprising: ahousing; a stator disposed in the housing; a rotor disposed in thestator; and a shaft disposed in the rotor, wherein the stator includes astator core, an insulator coupled to the stator core, and a coil woundon the insulator, wherein the stator core includes a head part and atooth protruded from the head part, wherein the insulator includes abody part in contact with the tooth and an edge part in contact with thehead part, and wherein the protrusion part is formed at the end of theedge part.
 15. The motor of claim 14, wherein one surface of theprotrusion part includes a curved shape and the curved shape is incontact with the coil.
 16. The motor of claim 14, wherein the statorcore includes a head part and a tooth part extending from the head part,and wherein at least a portion of the protrusion part is disposedoutside an end of the head part with respect to the body part.
 17. Themotor of claim 14, wherein a first side surface forms a first angle witha surface of the edge part, wherein a second side surface forms a secondangle with the surface of the edge part, and wherein the first angle isgreater than the second angle.
 18. The motor of claim 14, wherein afirst side surface forms a first angle with a surface of the edge part,wherein a second side surface forms a second angle with the surface ofthe edge part, and wherein the first angle is smaller than the secondangle.